Information injection-pump assembly
ZEXEL
106991-1121
1069911121
ISUZU
1156025304
1156025304
Rating:
Service parts 106991-1121 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-204-1
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106991-1121
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1121
1069911121
ISUZU
1156025304
1156025304
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve (drive side)
134424-4020
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-7-6-
5-4-3-10
-9-2
Pre-stroke
mm
4.2
4.17
4.23
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25
Cal 1-8 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25
Cal 1-7 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25
Cal 1-6 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25
Cal 1-5 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25
Cal 1-4 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25
Cal 1-3 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25
Cal 1-10 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25
Cal 1-9 deg. 288 287.75 288.25
Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
111.6
109.6
113.6
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
117.4
115.4
119.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.9+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.8
7.5
10.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
800+-30
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
2
1.5
2.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Damper spring setting
(3)Variable speed specification: idling adjustment
(4)Main spring setting
----------
----------
----------
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=150mm
----------
a=6deg+-5deg b=(21deg)+-5deg
----------
aa=150mm
----------
a=6deg+-5deg b=(21deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=40mm
----------
a=10deg+-5deg b=34deg+-3deg
----------
aa=40mm
----------
a=10deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
0000001201
(1)Variable speed specification
(2)Minimum - maximum speed specification
(3)Lever angle = c or less
(4)Use the hole at R = aa
----------
aa=130mm
----------
a=13deg+-5deg b=(20deg) c=26deg
----------
aa=130mm
----------
a=13deg+-5deg b=(20deg) c=26deg
0000001501 LEVER
2-stage changeover lever adjustment
(A) Speed lever
(B) Load lever
(C) 2-stage changeover lever
(D) Link
(E) Bolt
1. Minimum-maximum speed specification adjustment (when running)
(1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper.
(2)In this condition, the load lever is held in the idle position.
(3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L.
(4)Lock using the nut.
2. Variable speed specification adjustment (at operation)
(1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.)
(2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------
----------
L=1~2mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa (set timing)
(4)-
----------
aa=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
April 19, 2004
U-118
A-80
D-95
O-98
TT-10
TA-1
TM-3
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMANUFCTURED FUEL INJECTORS FROM DEALER PARTS STOCK
7750 PI70077
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
July 31, 2004PROBLEM
The injector nose cone may be undersize on certainremanufactured fuel injectors that are used in various 3116 Engines. All0R8461, 0R8463, 0R8465, 0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483,0R8633, 0R8682, 0R8684, and 0R8867 Remanufactured Fuel Injectors with DateCodes from 01/02/04 to 31/03/04 stamped on the box need to be removed fromdealer stock.ACTION REQUIRED
Remove all Remanufactured Fuel Injectors listedin the following chart from dealer parts stock that have Date Codes from01/02/04 to 31/03/04 stamped on the box.
Part Number Description Box Date Code
0R8461 INJECTOR GP 01/02/04 to 31/03/04
0R8463 INJECTOR GP 01/02/04 to 31/03/04
0R8465 INJECTOR GP 01/02/04 to 31/03/04
0R8469 INJECTOR GP 01/02/04 to 31/03/04
0R8471 INJECTOR GP 01/02/04 to 31/03/04
0R8473 INJECTOR GP 01/02/04 to 31/03/04
0R8475 INJECTOR GP 01/02/04 to 31/03/04
0R8479 INJECTOR GP 01/02/04 to 31/03/04
0R8483 INJECTOR GP 01/02/04 to 31/03/04
0R8633 INJECTOR GP 01/02/04 to 31/03/04
0R8682 INJECTOR GP 01/02/04 to 31/03/04
0R8684 INJECTOR GP 01/02/04 to 31/03/04
0R8867 INJECTOR GP 01/02/04 to 31/03/04
SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R8461, 0R8463, 0R8465,0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684,and 0R8867 Remanufactured Fuel Injectors that were removed from dealerparts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70077.***** All Dealers *****Return all 0R8461, 0R8463, 0R8465, 0R8469,0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684, and 0R8867Remanufactured Fuel Injectors that are removed from parts stock and a copyof the claim to:Caterpillar Inc.
Attn: Noe S. Perez - PI70077
Service Claims Room
8201 N. University
Peoria, IL 61615
U-118
A-80
D-95
O-98
TT-10
TA-1
TM-3
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMANUFCTURED FUEL INJECTORS FROM DEALER PARTS STOCK
7750 PI70077
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
July 31, 2004PROBLEM
The injector nose cone may be undersize on certainremanufactured fuel injectors that are used in various 3116 Engines. All0R8461, 0R8463, 0R8465, 0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483,0R8633, 0R8682, 0R8684, and 0R8867 Remanufactured Fuel Injectors with DateCodes from 01/02/04 to 31/03/04 stamped on the box need to be removed fromdealer stock.ACTION REQUIRED
Remove all Remanufactured Fuel Injectors listedin the following chart from dealer parts stock that have Date Codes from01/02/04 to 31/03/04 stamped on the box.
Part Number Description Box Date Code
0R8461 INJECTOR GP 01/02/04 to 31/03/04
0R8463 INJECTOR GP 01/02/04 to 31/03/04
0R8465 INJECTOR GP 01/02/04 to 31/03/04
0R8469 INJECTOR GP 01/02/04 to 31/03/04
0R8471 INJECTOR GP 01/02/04 to 31/03/04
0R8473 INJECTOR GP 01/02/04 to 31/03/04
0R8475 INJECTOR GP 01/02/04 to 31/03/04
0R8479 INJECTOR GP 01/02/04 to 31/03/04
0R8483 INJECTOR GP 01/02/04 to 31/03/04
0R8633 INJECTOR GP 01/02/04 to 31/03/04
0R8682 INJECTOR GP 01/02/04 to 31/03/04
0R8684 INJECTOR GP 01/02/04 to 31/03/04
0R8867 INJECTOR GP 01/02/04 to 31/03/04
SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R8461, 0R8463, 0R8465,0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684,and 0R8867 Remanufactured Fuel Injectors that were removed from dealerparts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70077.***** All Dealers *****Return all 0R8461, 0R8463, 0R8465, 0R8469,0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684, and 0R8867Remanufactured Fuel Injectors that are removed from parts stock and a copyof the claim to:Caterpillar Inc.
Attn: Noe S. Perez - PI70077
Service Claims Room
8201 N. University
Peoria, IL 61615